Composite wheel assembly and method of manufacturing

ABSTRACT

A composite wheel assembly and method of fabricating the same is provided. The wheel assembly includes a composite wheel rim, a wheel center, and a plurality of attachment fasteners for attaching the wheel center to the wheel rim. The wheel rim includes a plurality of attachment inserts that are configured to selectively engage with respective attachment fasteners. Each attachment insert is encapsulated by a plurality of composite layers of the wheel rim or is otherwise secured to the wheel rim. The attachment inserts extend from and/or are positioned within a drop well region of the wheel rim. The method of fabricating the wheel assembly includes forming first and second preforms and positioning the same onto a mold assembly. The method further includes positioning the attachment inserts between the first and second preforms such that the attachment inserts are secured therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/628,440, entitled “Composite Wheel Assembly”,which was filed on Feb. 9, 2018 and which is hereby incorporated byreference.

FIELD OF THE INVENTION

The present disclosure relates generally to composite structures andrelated attachment systems and methods. More specifically, the presentdisclosure is concerned with a wheel assembly having a composite wheelrim and a wheel center selectively attached thereto.

BACKGROUND OF THE INVENTION

Wheel structures, and in particular automotive wheel structures, are incommon use. A traditional automotive wheel includes a wheel rim portionand a wheel center portion. The wheel rim portion is the portion of thewheel that is disposed radially outward, and includes an axially innerand outer rim portion to which a traditional inflatable tire is secured.A rim body portion extends axially between the inner and outer rimportions.

The wheel center portion is the portion of the wheel that extendsradially outward from the axial and rotational center of the wheel, andis typically disposed at an axially outer location of the wheel, andprovides a mounting pattern to attach the wheel to corresponding bolts,lugs, studs, or the like that are coupled to the drive axle.

Various wheel constructions are known, including steel wheels,aluminum/alloy wheels, or composite wheels. Steel wheels are heavierthan aluminum wheels, but are stronger than aluminum wheels. Aluminumwheel, while being lighter weight, are softer and more susceptible tobending.

Composite wheels and other composite structures provide several benefitsover traditional materials. For instance, composite wheels providerelatively high strength, corrosion resistance, and durability at arelatively low weight. As such, composite wheels have becomeincreasingly popular. As composite wheels continue to grow inpopularity, users continue to desire new ways to enhance or otherwisechange the appearance of such wheels by installing specialized and/ordifferent wheel centers or other features on to the wheel rim.

Consequently, it would be beneficial to have a composite wheel assemblythat is configured to allow a user to selectively change one or more ofthe wheel center or other feature of the wheel assembly. Furthermore, itwould be beneficial if the wheel rim included a robust attachmentfeature for ensuring a secure attachment of such wheel center and/orother feature to such wheel rim. Furthermore still, it would bebeneficial to have a method and/or process for fabricating a wheel rimhaving such features and/or capabilities.

SUMMARY OF THE DISCLOSURE

It is an aspect of the present disclosure to provide a composite wheelwith a removable wheel center.

It is a further aspect of the present disclosure to provide a compositewheel with a strong attachment interface for a removable component.

It is a further aspect of the present disclosure to provide a method formanufacturing a composite wheel rim that enables the inclusion of anattachment interface for securing removable components.

In view of the above and the other aspects, a composite wheel assemblyis provided that includes a composite wheel rim having a radially innersurface and a radially outer surface. A plurality of attachment insertsare disposed radially between the radially inner surface and theradially outer surface of the wheel rim. A wheel center is attached tothe composite wheel rim via at least one fastener, wherein the fastenerengages at least a portion of the attachment insert.

In another aspect, a method of forming a wheel assembly is provided, themethod includes providing a mold for a wheel, the mold including anaxially inner end, an axially outer end, and a radially outer surface.The mold can include a drop well region having an outer diameter that isreduced relative to the radially outer surface.

The method can include advancing a first layer of material over theradially outer surface and the drop well region and inserting the firstlayer of material inward into the drop well region. The method canfurther include placing an attachment insert into the drop well regionover the first layer of material.

The method further includes advancing a second layer of material overthe first layer of material and the attachment insert. Additionally, themethod includes curing the first and second layers of material to form awheel rim, and retaining the attachment insert between the first andsecond layers of material.

In yet another aspect, a composite wheel apparatus is provided,including a composite wheel rim having a radially inner surface and aradially outer surface extending between an axially inner end and anaxially outer end. A first layer of composite material defines theradially inner surface, and a second layer of composite material definesthe radially outer surface.

A plurality of attachment inserts may be spaced apart circumferentiallyand disposed radially between the first layer of material and the secondlayer of material. The inserts are disposed axially closer to theaxially outer end than the axially inner end. The inserts are configuredto support a wheel center attached to the composite wheel rim.

In yet another aspect, a method of forming a wheel rim is provided. Themethod includes providing a mold for a wheel, wherein the mold has ashape and includes an axially inner end an axially outer end and aradially outer surface. The method further includes providing a firsttube preform of composite material and advancing the tube preformaxially over the mold. The method further includes draping the tubepreform against the radially outer surface of the mold; and shaping thetube preform to match the shape of the mold.

In yet another aspect, a wheel assembly is provided. The assemblyincludes a composite wheel rim having a radially outer surface and aradially inner surface, and a plurality of circumferentially disposedinserts disposed radially between a first ply stack and a second plystack, wherein the first ply stack is disposed radially inward relativeto the second ply stack. Each of the inserts includes a bore extendingtherethrough, wherein an axis of the bore enters and exits a radiallyouter volume defined by the first play stack.

In yet another aspect, a method of producing a wheel preform isprovided. The method includes creating a substantially straight walltube preform having one or more layers of composite material, providinga contoured mold for a wheel rim, advanced the tube preform over atleast a portion of the contoured mold, and draping the tube preform to acontoured shape on the contoured mold.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred aspect of the disclosure, illustrative of the best mode inwhich the applicant has contemplated applying the principles, is setforth in the following description and is shown in the drawings and isparticularly and distinctly pointed out and set forth in the appendedclaims.

FIG. 1 is a perspective view of a wheel assembly according to an aspectof the disclosure, the wheel assembly having a wheel rim and a wheelcenter attached thereto.

FIG. 2 is a perspective view of the wheel rim of FIG. 1.

FIG. 3A is a perspective view of a plurality of inserts andcorresponding spacers associated with certain aspects of the wheel rimof FIG. 2, FIG. 3A further showing fasteners extending from each insert.

FIG. 3B is a perspective view of a plurality of inserts associated withcertain embodiments of the wheel rim of FIG. 2.

FIG. 3C is a perspective view of a multi-material insert.

FIG. 4 is a sectional view of the wheel rim of FIG. 2, the cut takenthrough a center of a first insert positioned in an upper region of thewheel rim.

FIG. 5 is a detail view of the sectional view of FIG. 4 shown on anenlarged scale.

FIG. 6 is a sectional view of the detail view of FIG. 5, the cut takenthrough a center of a fastener hole of the first insert.

FIG. 7 is a sectional view of FIG. 6 showing a sectional view of afastener extending through the fastener hole of the first insert, thefastener shown engaged with a sectional view of the wheel center of FIG.1.

FIG. 8 is the sectional view of FIG. 7 showing an inboard seal plateextending over an inboard opening of the fastener hole of the firstinsert.

FIG. 9 is a sectional perspective view of a mold assembly of the presentdisclosure, the mold assembly having opposed inner and outer portionsand a center portion extending there between.

FIG. 10 is a perspective view of a first tube preform of the presentinvention, the first tube preform shown in a first configuration.

FIG. 11 is a perspective view of the first tube preform of FIG. 10, thefirst tube preform shown in a second configuration.

FIG. 12A is a sectional perspective view of the first tube preform ofFIG. 10 aligned with the mold assembly of FIG. 9, the first tube preformbeing in a second configuration, as shown in FIG. 11, and the innerportion of the mold assembly being removed.

FIG. 12B is a perspective view of a tube preform have a greater diameterthan the mold assembly.

FIG. 13 is a sectional view of the first tube preform being positionedon the mold assembly.

FIG. 14 is detail view of the stack-up of FIG. 13 shown on an enlargedscale.

FIG. 15 is a sectional view of the stack-up of FIG. 14, the first tubeshown in a third configuration draped against the mold assembly.

FIG. 16 is a detail view of the stack-up of FIG. 15 shown on an enlargedscale.

FIG. 17 is a sectional perspective view of a second tube preform alignedwith the stack-up of FIG. 15, the second tube preform being in a secondconfiguration, similar to the second configuration of the first tubepreform as shown in FIG. 11.

FIG. 18 is a sectional view of the second tube preform being positionedon the stack-up of FIG. 15.

FIG. 18A is detail view of the stack-up of FIG. 18 shown on an enlargedscale.

FIG. 19 is the detail view of FIG. 18A showing the second tube preformin a third configuration draped in a similar manner as the first tubepreform.

FIG. 20 is the detail view of FIG. 19 showing the first and second tubepreforms in respective fourth configurations.

FIG. 21 is a perspective sectional view of the stack-up of FIG. 20showing an inner portion of the mold assembly being reinstalled to acenter portion of the mold assembly.

FIG. 22 is a perspective view of another aspect of the wheel rimillustrating a non-revolute inner surface.

FIG. 23 is a perspective sectional view of the wheel rim of FIG. 22.

FIG. 24 is a perspective sectional view of the wheel rim of FIG. 22.

FIG. 25 is a partial side view of the wheel rim of FIG. 22.

FIG. 26 is a sectional view of the wheel rim of FIG. 22 taken along theline 26-26 of FIG. 25.

FIG. 27 is a partial perspective view of another aspect of the wheel rimillustrating a revolute inner surface.

FIG. 28 is a partial perspective view of the wheel rim of FIG. 27illustrating a non-revolute outer surface.

FIG. 29 is partial perspective view of the wheel rim of FIGS. 27 and 28illustrating an insert extending radially outward from the revoluteinner surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIGS. 1-3B, a system 10 may include a wheel assembly12 having a wheel rim 14 and a wheel center 16. The wheel rim 14 may bein the form of a composite wheel rim formed from one or more preforms,which are further described below. Each preform may include one or morelayer of material, such as one or more layer of elongated fibers and/orpolymer or non-polymer materials. As used herein, the term “layer”refers to a stack or a ply stack, which may be one or more layers ofmaterial. It will be appreciated that unless otherwise noted, referenceto a layer shall not be interpreted as only one layer of material. Forexample, many layers of material could be included as part of a stack orply stack, which combine to form the overall layer. The wheel center 16may be selectively attached and detached from the wheel rim 14, suchthat the wheel center 16 may be replaced with another type of wheelcenter 16 having a different appearance or different features to suitthe particular needs of the user.

FIG. 1 illustrates the wheel rim 14 and the wheel center 16 attached toeach other to define the overall wheel 12. FIG. 2 illustrates the wheelcenter 16 removed from the wheel rim 14, thereby allowing for the wheelcenter 16 to be replaced or reinstalled on the wheel rim 14

As shown in FIG. 2, the wheel rim 14 may define a plurality of radiallyand circumferentially spaced apertures 18 extending axially through oneor more layer of the wheel rim 14. The apertures 18 are shown in FIG. 2as being arranged in spaced apart pairs, with five pairs being showngenerally evenly spaced about the circumference of the wheel rim 14.However, the apertures may be arranged in a variety of other suitableways.

FIG. 1 illustrates the wheel center 16 with five spokes 20 that areevenly spaced and radiating from a hub portion 22 of the wheel center16. The spokes 20 may be arranged and spaced to correspond to the pairsof the apertures 18 disposed about the wheel rim 14. In the illustrationof FIGS. 1 and 2, the five spokes 20 correspond to the five pairs ofapertures 18. However, it will be appreciated that a different number ofspokes 20 and apertures 18 could also be used such that the wheel center16 may be securely attached to the wheel rim 14. The number andarrangement of spokes 20 need not match the number of pairs or groups ofapertures 18. For example, some apertures 18 may go unused. Moreover,the apertures 18 need not be arranged in pairs. For example, oneaperture 18 may be used to attach one spoke 20, or three apertures 18may be used to attach one spoke. In the case of a group of apertures 18,the apertures 18 need not have the same radial distance from the axialcenter of the wheel 12. For example, multiple apertures 18 may bearranged at different radial distances. Moreover, multiple apertures maybe disposed in the same radial direction and spaced apart at differentradial distances. It will be appreciated that various other combinationsand spacing of the apertures 18 on the wheel rim 14 are contemplated.

With regard to the wheel center 16, it will be appreciated that thewheel center 16 need not be in the hub-and-spoke arrangement shown inFIG. 1. In another aspect, the wheel center 16 may be in the form of adisc. In the case of the spokes 20, the spokes 20 may be unevenlyspaced. It will be appreciated that various shapes of the wheel center16 are contemplated.

With reference to FIGS. 3A-3C, in one aspect, the wheel rim 14 mayinclude a plurality of circumferentially spaced attachment inserts 30for providing selective attachment points for attaching the wheel center16 to the wheel rim 14. Each attachment insert 30 may be aligned withone or more attachment aperture 18 and may be configured to receive oneor more fasteners 32 (such as a bolt or stud, more clearly shown inFIGS. 7 and 8) for selectively securing the wheel center 16 to the wheelrim 14. It will be appreciated that other objects may also be attachedto the wheel rim 14 via the apertures 18 and inserts 30.

In one aspect, shown in FIGS. 7 and 8, the wheel center 16 may defineinternal threads 34 that are configured to selectively engage with athreaded region of a respective attachment fastener 32, thereby allowingthe wheel center 16 to be attached to the wheel rim 14 by extending theattachment fasteners 32 into engagement with respective threads 34 ofthe wheel center 16. In this approach, the fasteners 32 may be passedfrom the inner side of the wheel rim 14 and toward the outer side,thereby engaging the wheel center 16 that is placed on the outer side ofthe wheel rim 14.

In another aspect, the wheel center 16 may define a plurality of throughholes 36 (FIG. 7), similarly disposed about the wheel center 16 like thethreads 34 described above, such that the wheel center 16 can beattached to the wheel rim 14 by extending a plurality of attachmentfasteners 32 through respective through holes 36 of the wheel center 16.In this approach, the fasteners 32 may be passed through the wheel rim14 and the wheel center 16 from either direction. The wheel center 16may include a counter-bore at the location of the holes 36 to receivethe head of the fastener 32, if desired.

In one aspect, a plurality of secondary fasteners (not shown), such asnuts, clips, or the like, may be included and configured to secure torespective attachment fasteners 32 that extend through the holes 36,thereby securing the wheel center 16 to the wheel rim 14. In someaspects, one or more secondary fasteners may be secured to or otherwiseengaged with the wheel center 16 and/or the wheel rim 14 independent ofits engagement with a respective attachment fastener.

In yet another aspect, the attachment fasteners 32 may extend from thewheel center 16 into respective attachment inserts 30. In this approach,the attachment insert 30 may define a threaded section 38 havingcorresponding threads (not explicitly shown) for selective engagementwith respective threaded regions of the attachment fasteners 32. Inanother approach, the attachment inserts 30 may be configured to allowselective engagement of each attachment fastener with one or morerespective secondary fasteners.

With reference to FIGS. 4-6, in one aspect, radially inner and outersurfaces 14 a and 14 b of the wheel rim 14 may be defined, at least inpart, by a respective first layer 40 and a second layer 42 of material(further described below and shown in FIG. 19). At least a portion ofthe outer surface 14 b of the wheel rim may define at least a portion ofa pressure barrier associated with a sealed volume of a wheel/tireassembly when the tire is mounted to the wheel rim 14.

In one aspect, the second layer of material 42 extends radially betweenthe attachment inserts 30 and the sealed volume, thereby preserving thepressure barrier. The first layer of material 40 may extend radially andlaterally around the attachment inserts 30, thereby fully encapsulatingthe attachment inserts 30. With reference to FIG. 6, the first layer 40may extend around the bottom and sides of the insert 30, with the top ofthe insert 30 being covered by the second layer 42.

In another aspect, the attachment inserts 30 may not be fullyencapsulated and may be otherwise secured to the wheel rim 14. In someaspects, the attachment inserts 30 may include one or more roughenedsurface treatments and/or one or more feature or array of features, suchas one or more spikes, or the like, to facilitate integration of theattachment inserts 30 with one or more of the layers 40, 42 (oradditional layers) of the wheel rim 14.

With reference to FIGS. 3A and 3B, the wheel rim 14 may include aplurality of the attachment inserts 30, as described above, therebydefining a first hole pattern. The first hole pattern is configured tocorrespond with a second hole pattern associated with the wheel center16, similar to that described above with respect to the apertures 18,such as a second hole pattern associated with the illustrated 5-spokewheel center, and/or with one or more of a variety of hole patternsassociated with one or more other wheel centers.

In one aspect, the wheel rim 14 includes a first number of attachmentinserts 30 and the wheel center 16 includes a second number of spokes 20or other features. In some embodiments, the first number is less thanthe second number such that one or more attachment insert 30 isconfigured to provide attachment support for more than one spoke 20and/or other feature of the wheel center 16.

With reference to FIG. 3A, in an aspect, the inserts 30 may be attachedto each to define a ring 44 that is disposed in the wheel rim 14. Atleast part of the ring 44 is formed by a plurality of spacer inserts 46extending radially between the attachment inserts 30. In another aspect,the attachment inserts 30 are formed in a continuous ring of material,such that no spacers are required. In another aspect, the spacers 46 andattachment inserts 30 are integrated together in the attachment ring 44,such as by bonding the spacer inserts 46 to respective attachmentinserts 30, or otherwise attached.

In one approach, each attachment insert 30 (or a continuous ring ofmaterial that includes the attachment insert) is formed, at least inpart, from metal, plastic, and/or some other high-strength, rigidmaterial now known or later developed. In some aspects, each spacer 46is formed, at least in part, from a lightweight and/or inexpensivematerial, such as foam or the like. FIG. 6-8 illustrate the inserts 30being formed of a single material type. However, as shown in FIG. 3C,the insert 30 may be formed by multiple material types, and may includea body portion 30 a and a bushing portion 30 b. In one aspect, thebushing portion 30 b may be made of a higher-strength material than thebody portion 30 a, such that the bushing portion 30 b may receive alarger installation load for supporting the fastener 32. It will beappreciated that other multi-material or multi-component insertconstructions could also be used.

In one aspect, the wheel rim 14 may include a continuous spacer ringconstructed primarily of foam or some other low-strength material. Insome such embodiments, the spacer ring includes a steel sleeve insert,which may be considered the attachment insert 30, and/or one or moreother high-strength portion positioned at or near one or more desiredattachment locations.

As shown in FIG. 3B, the attachment inserts 30 may be spaced apart andnot connected to each other by spacer inserts or the like, and the wheelrim 14 may define distinct insert regions (not explicitly shown). Theseinsert regions in the wheel rim 14 may be formed by a corresponding moldshape, which includes a depression or cavity at the distinct regionsthat will receive the inserts 30.

In this approach, each distinct insert region is configured to alignwith one or more corresponding spoke 20 or other feature of a respectivewheel center 16. In one aspect, shown in FIG. 3B, each attachment insert30 may include opposed transition sections 48 disposed on oppositecircumferential sides of the insert 30. In this approach, eachtransition section 48 may be configured to facilitate a flow ofcomposite material over at least a portion of such transition section 48and over at least a portion of the attachment insert 30 as a whole,thereby facilitating securement of the attachment inserts 30 to thewheel rim 14 by positioning at least a portion of each attachment insert30 between the first and second layers 40, 42 of material.

In one aspect, as shown in FIGS. 4-8, the attachment inserts 30 may bepositioned in a drop well region 50 of the wheel rim 14. In oneapproach, the drop well region 50 defines an inner surface 50 a and anouter surface 50 b that are opposed to each other, and a plurality ofbores 52 extending therebetween. In an aspect, the outer surface 50 b ofthe drop well region 50 is configured to interface with an inner surfaceof the wheel center 16, thereby sealing an outer opening of the bores 52as shown in FIGS. 7 and 8.

In one aspect, each bore 52 is defined at least in part by theattachment insert 30, as shown in FIGS. 6-8. The bores 52 may be adouble bore and/or a countersunk bore to allow a head of the respectiveattachment fastener 34 to be recessed within the drop well region 50.

In one aspect, shown in FIG. 8, an inboard seal plate 54 is secured tothe inner surface 50 a of the drop well region 50, thereby sealing aninner opening of the bore 52. In one approach, a plurality of localinboard seal plates 54 are positioned at each fastener location. In oneapproach, one or more inboard seal plates 54 extend over severalfastener locations. In one aspect, the inboard seal plate 54 is bolted,bonded, or otherwise secured in place. In some aspects, the inboard sealplate 54 may include one or more sealing membrane.

In another aspect, shown in FIGS. 7 and 8, an outboard seal 55, whichmay in the form of an o-ring seal or a dispensed sealant bead, may bedisposed axially between the wheel center 16 and the wheel rim 14. Whenthe wheel center 16 is secured to the wheel rim 14 by the fastener 32,the outboard seal 55 may be axially compressed between the wheel center16 and the wheel rim 14, thereby providing a seal around the fastener32.

With reference to FIG. 7, as an alternative to the seal plate 54, a sealplug 57 may be disposed in the inboard opening of the bore 52 to sealthe inboard end of the fastener 32. The seal plug 57 may be in the formof a dispensed sealant that may be injected into the inboard end of thebore 52, or the seal plug 57 may be a skived RTV (room temperaturevulcanizing) material. Thus, whether using the sealing plate 54 or theseal plug 57, the inboard side of the bore may be sealed.

As shown in FIGS. 6-8, the fastener 32 and the bore 52 has beenillustrated as having an axial orientation. It will be appreciated thatthe axis of the fastener 32 through the insert 30 and the axis of thebore 52 need not be perfectly axial or aligned with the axis of thewheel 12. Indeed, the axis of the fastener 32 and the bore 52 may bedisposed at an angle relative to the axis of the wheel 12.

The present disclosure further includes a method of forming the wheelrim 14 with the inserts 30. FIGS. 9-21 illustrate various structure andsteps associated with forming the wheel rim. In one aspect, the methodincludes utilizing a mold assembly 60 (FIG. 9) during one or more lay-upprocesses to form one or more features of the wheel rim 14. In oneaspect, at least one lay-up step includes positioning the first layer 40of material on the mold assembly 60 and/or draping the first layer 40 ofmaterial to the mold assembly. The process may further include forming afirst preform 62 that is configured to be positioned on and/or draped tothe mold assembly 60. The first preform 62 may include the first layer40 of material.

In one aspect, the first preform 62 and/or one or more other preform mayinclude one or more layer of reinforcement materials. The layers mayprovide varying degrees of coverage. In some aspects, one or more layerof the preform 62 and/or wheel rim 14 includes an orientation, material,and/or thickness that differs from one or more other layer of therespective preform 62 and/or wheel rim 14. In some aspects, one or morelayer of material of the wheel rim 14 includes a plurality of elongatedfiber materials and/or a polymer and/or non-polymer matrix. In oneaspect, a polymer and/or non-polymer matrix is added to one or morefiber layer and/or other layer prior to, during, and/or after a firstlay-up step, a last lay-up step, and/or one or more intermediate lay-upstep.

In one aspect, shown in FIG. 9, the mold assembly 60 includes an innerportion 60 a, an outer portion, 60 b and a center portion 60 c extendingtherebetween. In one aspect, the outer portion 60 b of the mold assemblymay include an outer lip 60 d for forming an outer flange of the wheelrim 14, such as an outer bead of the wheel rim 14. The outer portion 60b and/or the center portion 60 c may define a recessed area 60 e forforming the drop well region 50 of the wheel rim 14. In some aspects,the inner portion 60 a of the mold assembly 60 includes an inner lip 60f for forming an inner flange of the wheel rim 14, such as an inner beadof the wheel rim 14.

In one aspect, the method of forming the wheel rim 14 may includedraping a plurality of layers of composite material such that theyfollow one or more feature of the mold assembly 60. The method mayfurther include positioning one or more inserts 30 between one or morelayer of material, thereby fully or partially encapsulating the inserts30 therein and/or otherwise securing the inserts 30 to the layers ofmaterial. For the purposes of discussion, the first and second layers40, 42 will be referenced. However, it will be appreciated that multipleother layers could be applied to the mold assembly 60 before and/orafter placing the inserts 30 on the mold assembly 60.

In one approach, illustrated in FIG. 10, the method includes forming thefirst preform 62 in the form of a tube (a “first tube preform 64”). Thefirst tube preform 64 may be formed using a largely featureless tool(not shown). The tube preform 64, and any other tube preforms describedherein, may be formed via roll wrapping. In this process, one or morelayers of composite material may be provided in roll form and wrappedcircumferentially to form a tubular shape. The forming of the tubularshape may be performed over a male mandrel, on the interior of a roundcavity, or without the use of a forming tool. The forming may also occurwith the tubular shape in a vertical or horizontal orientation. Buttsplices, underlaps, or overlaps may be used to terminate individual ormultiple material layers. In the case of the tube preform havingmultiple layers, the layers may be different materials and may havedifferent material orientations. Film adhesive, tackifier, or othercommon material and methods can be used to stabilize the preform,thereby allowing the preform to maintain the predominantly tubular shapeduring subsequent operations.

The first tube preform 64 may be configured to slide over at least partof the mold assembly 60 so as to allow the first tube preform 64 to bedraped thereon, thereby forming the first layer 40 of the wheel rim 14.As described above, the first layer 40 of the wheel rim 14 may define aninner surface of the wheel rim 14 when the wheel rim 14 has been formed.

In one aspect, an inner diameter of the first tube preform 64 is smallerthan an outer diameter of the inner portion 60 a of the mold assembly60. In this approach, the method may include removing the inner portion60 a of the mold assembly 60 prior to engaging the first tube preform 64with the mold assembly 60. FIG. 12A illustrates the mold assembly 60with the inner portion 60 a removed.

In one approach, the inner diameter of the first tube preform 64 isgenerally equivalent to an outer diameter of a distal end of the centerportion 60 c of the mold assembly 60, as shown in FIG. 13, therebyallowing the first tube preform 64 to engage with the mold assembly 60by sliding the first tube preform 64 over the distal end of the centerportion 60 c of the mold assembly 60, as illustrated in FIGS. 12 and 13.

In another aspect, the tube preform 64 may be inserted onto the moldassembly 60 from the outboard side of the mold assembly 60. In thisapproach, the outer portion 60 b of the mold assembly 60 may be removedto facilitate installation of the tube preform 64.

In one approach, additional preforms 65 are installed after or beforethe first tube preform in localized portions of the mold assembly 60corresponding to localized portions of the resulting wheel rim 14 aftermolding and curing. FIG. 14 illustrates the additional preform 65 beinginstalled over the first preform 64 on the mold assembly 60. In oneapproach, the localized preforms 65 are placed corresponding to the beadregions of the rim 14 to provide reinforcement in the bead regions.

In some aspects, the tube preform 64 diameter may be greater than theouter diameters of the mold assembly 60. In this approach, the tubepreform 64 may be installed without removing a portion of the moldassembly 60. An example of this arrangement is illustrated in FIG. 12B,in which the tube preform 64 is shown with a larger diameter than themold assembly 60, such that the sections of the mold assembly are shownin an assembled state without removal of the outer portion.

With reference to FIG. 11, in one aspect, the method includes folding aproximal end of the first tube preform 64 so as to form at least part ofa first radial flange 64 a, such as at least part of an outer beadflange of the wheel rim 14, thereby moving the first preform 64 from afirst configuration to a second configuration. In this approach, themethod may include moving the first radial flange 64 a into engagementwith the outer lip 60 d of the mold assembly 60 while the first tubepreform 64 remains generally in its second configuration, as shown inFIG. 14. In one approach, the method may include draping the first tubepreform 64 against the outer portion 60 b of the mold assembly 60 and/oragainst the center portion 60 c of the mold assembly 60 whilemaintaining engagement of the first radial flange 64 a with the outerlip 60 d of the mold assembly 60, thereby moving the first tube preform64 to a third configuration, as shown in FIG. 15.

In one aspect, one or more biasing items is utilized to move the firsttube preform 64 to the third configuration and/or to retain the firsttube preform 64 in the third configuration. For example, the biasingitems may include a high-strength strand material, reinforcement fiber,one or more vacuum bag, one or more bladder, and/or one or more rollerand/or actuator. In some aspects, utilization of the biasing itemsincludes winding such biasing item around the preform 64, such as byturning the mold 60, positioning such biasing item against and/or intoclose proximity with the first tube preform 64, and/or inflating,deflating, and/or actuating one or more such biasing item. In someembodiments, one or more preform 64 and/or layer of material is drapedagainst an external mold and/or an external feature of one or more mold.In this approach, one or more biasing item is utilized to move thepreform 64 and/or layer of material into engagement with one or morefeature, such as by positioning one or more bladder into close proximityto such preform and/or layer of material and inflating and/or otherwiseexpanding such bladder and/or bladders so as to bias such material intoposition.

In one aspect, one or more full or partial preform and/or layer ofmaterial 65 (“additional layer of material”) is positioned on and/orotherwise draped onto the first tube preform 64. In some aspects, one ormore additional layer of material 65 is configured to createpredominately axially oriented stiffeners in the well region 50 thatreceives the insert 30 of the wheel rim 14 and/or to otherwise createand/or contribute to the creation of one or more stiffened region of thewheel rim 14. An example of this approach is shown in FIG. 14. Inanother approach, one or more additional layer of material 65 is drapedonto the first tube preform 64 while the first tube preform 64 is in thethird configuration shown in FIG. 15.

With reference to FIG. 16, in one aspect, the method includespositioning one or more attachment inserts 30 and/or spacer insert 46into position relative to the first tube preform 64. In one aspect, themethod includes positioning the one or more insert 30 into the recessedarea 60 e of the mold assembly 60.

The method may further include positioning one or more additional layerof material 65 on and/or adjacent to one or more insert 30 that has beenplaced within the recessed area 60 e, thereby encapsulating such insert30 and/or otherwise creating an attachment feature for securing suchinsert to such wheel rim. In some aspects, one or more other material,such as a fiber material, a polymer material, a non-polymer material,and one or more other material is used to encapsulate and/or to securethe one or more insert 30 to one or more layer of material.

With reference to FIGS. 17-19, the method may further include forming asecond preform in the form of a tube (a “second tube preform 66”). Insome embodiments, the second tube preform 66 is substantially similar tothe first tube preform 64, and may be shaped or adjusted in shape in asimilar manner as that described above. In one approach, the second tubepreform 66 may be shorter in length than the first tube preform 64. Inanother approach, the second tube preform 66 may be longer in lengththan the first tube preform 64. In one approach, the second tube preform66 is formed using a largely featureless tool.

The second tube preform 66 may be configured to slide over at least partof the first tube preform 64 while the first tube preform is in itsthird configuration. FIGS. 17-18A illustrate the second tube preform 66sliding over the first tube preform 64. The second tube preform 66 maybe configured to slide over a plurality of inserts 30 associated withthe first tube preform 64, thereby encapsulating such inserts 30 withinthe wheel rim 14 and/or otherwise securing such inserts 30 to the wheelrim 14.

With reference to FIG. 19, in one aspect, the second tube preform 66 isconfigured to be draped onto the first tube preform 64, one or moreinsert 30, and/or one or more additional layer of material, asapplicable, thereby forming the second layer 42 of the wheel rim 14. Thesecond layer 42 of the wheel rim 14 may define the outer surface 14 b ofthe wheel rim 14. Thus, at least a portion of the second layer 42 of thewheel rim 14 may form at least a portion of a pressure barrier of thewheel rim 14.

In one approach, an inner diameter of the second tube preform 66 isgenerally equivalent to an outer diameter of the first tube preform 64when measured at a distal end of the center portion 60 c of the moldassembly 60 (shown in FIG. 19), thereby allowing the second tube preform66 to engage with the first tube preform 64 by sliding the second tubepreform 66 over the first tube preform 64.

With reference to FIG. 17, in one approach, the method may includefolding a proximal end of the second tube preform 66 so as to form atleast part of a first radial flange 66 a, such as at least part of anouter bead flange of the wheel rim 14, thereby moving the second tubepreform 66 from a first configuration (similar to that shown in FIG. 10for the first preform 64) to a second configuration. The method mayinclude moving the first radial flange 66 a of the second tube preform66 into engagement the first radial flange 64 a of the first tubepreform 64. The method may further include draping the second tubepreform 66 against the first tube preform 64, against one or more insert30, and/or against one or more additional layer of material, asapplicable, thereby moving the second tube preform to a thirdconfiguration, as shown in FIG. 19.

In one aspect, one or more biasing items is utilized to move the secondtube preform 66 to its third configuration and/or to retain the secondtube preform 66 in its third configuration. The biasing items mayinclude high-strength strand material, reinforcement fiber, one or morevacuum bag, one or more bladder, and/or one or more roller and/oractuator. In one approach, utilization of the biasing items includeswinding such biasing item around the preform, such as by turning themold, positioning such biasing item against and/or into close proximitywith the first tube preform, and/or inflating, deflating, and/oractuating one or more such biasing item.

With reference to FIG. 20, a distal end of the first tube preform 64,the second preform 66, and/or one or more additional layer of materialis folded to facilitate reinstallation of the inner portion 60 a of themold assembly 60, thereby moving the first and/or second tube preform64, 66 into a respective fourth configuration. In one approach,additional preforms may be installed before moving the preforms into afourth configuration.

With reference to FIGS. 20 and 21, in one approach the folded portion ofrespective preforms 64, 66 and/or layers of material are draped againstthe inner portion 60 a of the mold assembly 60, thereby moving suchpreforms and/or layers of material to a final configuration and/orforming an inner flange 64 a, 66 a of the wheel rim 14, such as an innerbead of the wheel rim 14.

In one approach, one or more additional layer of material is positionedon and/or otherwise draped onto the first and/or second tube preform 64,66, onto one or more insert, and/or onto one or more other additionallayer of material while the first and/or second tube preform 64, 66 isin a third or fourth configuration and/or when the wheel rim 14 is inthe final configuration and/or as the wheel rim 14 is moved to its finalconfiguration. The one or more additional layer of material may beconfigured to create predominately axially oriented stiffeners in aninsert region of the wheel rim 14 and/or to otherwise create and/orcontribute to the creation of one or more stiffened region of the wheelrim 14.

The method may further include curing the wheel rim 14 and/or removingthe wheel rim 14 from the mold assembly 60 prior to drilling one or moreof the bores 52 through one or more attachment insert 30 of the wheelrim 14. In one approach, the wheel center 16 is secured to the wheel rim14 utilizing one or more attachment fastener 34 and one hole associatedwith such attachment fasteners 34 is sealed utilizing one or more sealplates 54. In one aspect, one or more attachment insert 30 is boredprior to being installed within and/or to a wheel rim 14. In thisapproach, the wheel rim 14 may be bored or machined as desired toprovide access to the bore 52 formed in the insert 30.

As shown throughout the Figures already discussed, the mold assembly 60has a “revolute” trough or the like that defines a wheel rim 14 with arevolute inner geometry, such that the inner diameter below the firstlayer 40 is generally constant. However, in another aspect, the wheelrim 14 may be formed with a non-revolute inner geometry. An example ofthe non-revolute inner geometry is shown in FIG. 22.

As shown in FIGS. 22-26, the geometry of the wheel rim 14 that housesthe inserts 30 may project toward the center relative to the innerdiameter of the wheel rim 14. Accordingly, the wheel rim 14 may includea plurality of insert projections 14 a that include the inserts 30disposed therein. In this approach, the first layer 40 remains the firstlayer to be applied to the mold assembly 60 as a preform, with theinserts 30 being disposed over the first layer 40, and the second layer42 is disposed over the inserts 30 following their insertion. The moldassembly 60 may include a plurality of insert pockets (not explicitlyshown on the mold assembly 60) into which the first layer 40 may bedraped, with the inserts 30 thereafter positioned into the pocketsformed in the first layer 40.

The inserts 30, after being placed into the pockets, may be generallyflush with the non-pocketed portion of the first layer 40, such that thesecond layer 42 that is subsequently applied will have a generally flatprofile. Thus, the outer diameter of the wheel rim 14 may beaxisymmetric (revolute), while the inner diameter is non-axisymmetric(non-revolute). Alternatively, the inserts 30 may also project radiallyoutward from the non-pocketed portion of the first layer 40, and thesecond layer 42 may have an outer profile with radially outwardprojections, or the like. Thus, both the inner and outer diameters ofthe wheel rim 14 may be non-axisymmetric (non-revolute).

In another approach, shown in FIGS. 27-29, the inserts 30 may be placedover the first layer 40, which forms an inner revolute surface. Thisarrangement may be used with the inserts 30 shown in FIG. 3B, wherethere is no spacer ring between the inserts. This arrangement differsfrom the arrangement shown in FIG. 22-26 in that the inserts 30 do notproject radially inward relative to the rest of the inner surfacedefined by the first layer 40. Rather, the inserts 30 project radiallyoutward from the revolute first layer 40, and are covered by the secondlayer 42, such that the radially outer surface defined by the secondlayer 42 is non-revolute. Put another way, the second layer 42 is drapedover the top of the insert 30 and defines an axisymmetric trough on theradially outer surface of the wheel rim 14.

In the case of the inserts 30 including the spacer material 46 shown inFIG. 3A, the inner and outer radial surfaces defined by the first andsecond layers 40, 42 would both be revolute surfaces.

In each of the above aspects, the insert 30 has been disposed radiallybetween the first layer and the second layer (where each of these“layers” may be a combination of multiple layers of material or plies).In an axial direction, the insert 30 is disposed between axially innerand outer portions of the bottom layer/ply stack. When formed on themold assembly 60, the first layer 40 will form a radially inner surfaceand a radially outer surface, with the radially outer surface defining,in part, a radially outer volume, which corresponds generally to thesealed volume of the tire and wheel assembly when a tire is mounted.Thus, the fastener 32, or the axis of the fastener 32 will effectivelypass through the sealed volume of the tire and wheel assembly. Theinsert 30 itself is sealed from the sealed volume by the second layer,where the plies of the second layer cover the insert. Put another way,the fastener 32, or the axis of the fastener 32, enters and exits theouter volume defined by the first layer 40, which is made possible bythe provision of the insert 30 into this outer volume and the secondlayer 42 that covers the insert 30 and defines its own outer volume.

The foregoing and other objects are intended to be illustrative of thedisclosure and are not meant in a limiting sense. Many possibleembodiments of the disclosure may be made and will be readily evidentupon a study of the following specification and accompanying drawingscomprising a part thereof. Various features and subcombinations of thedisclosure may be employed without reference to other features andsubcombinations. Other objects and advantages of this disclosure willbecome apparent from the following description taken in connection withthe accompanying drawings, wherein is set forth by way of illustrationand example, an embodiment of this invention and various featuresthereof.

What is claimed is:
 1. A composite wheel assembly comprising: acomposite wheel rim having a radially inner surface and a radially outersurface; a plurality of attachment inserts disposed radially between theradially inner surface and the radially outer surface of the wheel rim;a wheel center attached to the composite wheel rim, wherein at least onefastener engages at least a portion of the attachment insert and securesthe wheel center to the composite wheel rim; at least one first layer ofcomposite material defining the radially inner surface; and at least onesecond layer of composite material defining the radially outer surface;wherein the attachment insert is disposed radially between the firstlayer of composite material and the second layer of composite material.2. The assembly of claim 1, wherein the radially outer surface isconfigured to enclose at least a portion of a sealed volume definedbetween the wheel rim and a tire when the tire is attached.
 3. Theassembly of claim 1, wherein the wheel rim defines a drop well regiondisposed radially between the radially inner and radially outersurfaces, and at least one of the plurality of inserts is disposed inthe drop well region.
 4. The assembly of claim 3, wherein a plurality ofspacer inserts are disposed circumferentially between circumferentiallyadjacent inserts and couple the plurality of inserts to each other. 5.The assembly of claim 4, wherein the spacer inserts are disposed in thedrop well region.
 6. The assembly of claim 3, wherein the plurality ofinserts are spaced apart circumferentially from each other and are notcoupled to each other.
 7. The assembly of claim 6, wherein the drop wellregion comprises a plurality of regions that are circumferentiallyspaced apart from each other, and a respective one of the inserts isdisposed in each of the plurality of regions.
 8. The assembly of claim1, wherein the inserts each include at least one bore therein.
 9. Theassembly of claim 8, wherein the wheel rim includes a plurality ofapertures in the wheel rim corresponding to the locations of the atleast one bore of the inserts.
 10. The assembly of claim 9 furthercomprising at least one sealing plate disposed over the plurality ofapertures that seals the apertures.
 11. The assembly of claim 9, whereinthe apertures and/or the at least one bore includes a sealant disposedwithin the at least one bore or a counter-bore portion of the at leastone bore.
 12. The assembly of claim 8, wherein the at least one boreincludes an enlarged diameter portion for receiving a head of a fastenertherein.
 13. The assembly of claim 1, wherein the wheel center includesa threaded portion, and the at least one fastener engages the threadedportion.
 14. The assembly of claim 1, wherein the radially inner surfaceis defined by a first surface of the at least one first layer ofmaterial and the radially outer surface is defined by a second surfaceof the at least one second layer of material.
 15. The assembly of claim1, wherein the insert is disposed axially between an axially innersurface and an axially outer surface.
 16. A composite wheel assemblycomprising: a composite wheel rim having a radially inner surface and aradially outer surface; a plurality of attachment inserts disposedradially between the radially inner surface and the radially outersurface of the wheel rim; a wheel center attached to the composite wheelrim, wherein at least one fastener engages at least a portion of theattachment insert and secures the wheel center to the composite wheelrim; wherein the radially inner surface, the axially inner surface, andthe axially outer surface are defined by at least one first layer ofmaterial.
 17. A composite wheel assembly comprising: a composite wheelrim having a radially inner surface and a radially outer surface; aplurality of attachment inserts disposed radially between the radiallyinner surface and the radially outer surface of the wheel rim; a wheelcenter attached to the composite wheel rim, wherein at least onefastener engages at least a portion of the attachment insert and securesthe wheel center to the composite wheel rim; wherein the insert isdisposed axially between an axially inner surface and an axially outersurface; wherein the radially inner surface, the axially inner surface,and the axially outer surface are defined by at least one first layer ofmaterial; wherein the at least one first layer of material defines aradially outer volume, and the at least one fastener enters and exitsthe radially outer volume through the axially inner and outer surfaces,and at least one second layer of material is disposed radially betweenthe at least one fastener and a sealed volume of a tire when a tire isinstalled on the wheel rim.
 18. A composite wheel apparatus comprising:a composite wheel rim having a radially inner surface and a radiallyouter surface extending between an axially inner end and an axiallyouter end; at least one first layer of composite material defining theradially inner surface; at least one second layer of composite materialdefining the radially outer surface; and a plurality of attachmentinserts spaced apart circumferentially and disposed radially between theat least one first layer of material and the at least one second layerof material, and further disposed axially closer to the axially outerend than the axially inner end, wherein the inserts are configured tosupport a wheel center attached to the composite wheel rim.
 19. Theapparatus of claim 18, wherein the inserts define at least one boreextending therethrough for receiving a fastener, where an axis of thebore enters and exits an outer volume defined by the at least one firstlayer.
 20. The apparatus of claim 19, wherein the inserts are sealed bythe at least one second layer from a tire sealed volume defined by aradially outer surface of the at least one second layer.
 21. Theapparatus of claim 18, wherein the wheel rim includes a revolute innersurface at an axial location corresponding to an axial location of theinserts.
 22. The apparatus of claim 18, wherein the wheel rim includes anon-revolute inner surface at an axial location corresponding to anaxial location of the inserts.
 23. The apparatus of claim 22, whereinthe at least one first layer of material defines a plurality of pocketsin which the inserts are disposed.
 24. A wheel assembly comprising: acomposite wheel rim having a radially outer surface and a radially innersurface; a plurality of circumferentially disposed inserts disposedradially between a first ply stack and a second ply stack, wherein thefirst ply stack is disposed radially inward relative to the second plystack; wherein each of the inserts includes a bore extendingtherethrough, wherein an axis of the bore enters and exits a radiallyouter volume defined by the first ply stack.
 25. The assembly of claim24 further comprising a wheel center attached to the wheel rim whereinfasteners extend at least partially through the bore of the inserts andsecure the wheel center to the wheel rim.
 26. The assembly of claim 24,wherein a radially inner surface of the first ply stack at an axiallocation corresponding to the inserts defines a revolute inner surface.27. The assembly of claim 24, wherein a radially inner surface of thefirst ply stack at an axial location corresponding to the insertsdefines a non-revolute inner surface.